Heated insole with removable and rechargeable battery

ABSTRACT

A heated insole for a shoe has an insole body and a battery. The insole body has a battery-receiving portion. The battery is configured to be removable from and insertable into the battery-receiving portion while the insole is disposed within the shoe.

RELATED APPLICATIONS

This application is a continuation of U.S. Nonprovisional applicationSer. No. 14/248,861, filed Apr. 9, 2014, which claims the benefit of andpriority to U.S. Provisional Application Nos. 61/947,913, filed Mar. 4,2014, and 61/911,835, filed Dec. 4, 2013. The entireties of each areincorporated by reference herein.

TECHNICAL FIELD

This application relates to insoles such as heated insoles that includea battery.

BACKGROUND

Several occupations require employees to endure harsh weather conditionsduring the winter months. To name a few, soldiers, construction workers,agricultural workers, and law enforcement officers must routinely spendseveral hours outdoors despite cold, snowy or icy conditions. Othershappily brave cold weather in order to enjoy activities such as skiing,hiking, snowshoeing, and sledding. Further, many must bear freezingtemperatures after a snowstorm to shovel their car out and to clearaccumulated snow from their driveway and/or sidewalk.

Regardless of whether one is exposed to cold weather conditions forwork, fun, or chores, most accessorize with coats, boots, hats, andgloves to make the cold weather bearable. In addition to thoseaccessories, heated insoles for shoes have recently been introduced inorder to provide heat directly to a wearer's feet. Known heated insolesinclude electronics located between an insole's layers. The heatedinsoles include an internal heating pad coupled to an internal battery.The internal battery, due its size, has a limited battery life (e.g.,3-4 hours). In order to charge the electronics, one must connect theheated insole to an electrical power source. This requirement is ahassle for those who desire warmth in excess of the battery life. Onemust remove the heated insole from the shoe, plug in the insole torecharge its internal battery, wait for the insole's internal battery torecharge, and then re-introduce the insole into the shoe prior tocontinuing with their activity.

SUMMARY

A battery-powered insole, according to the invention, allows a user toeasily remove and replace a battery without having to remove the insolefrom the shoe, and the user does not have to wait for the insole torecharge.

According to certain aspects, an insole of the invention includes aninsole body having a battery-receiving portion and a battery. Thebattery-receiving portion is configured such that the battery isremovable from and insertable into the insole body while the insole isdisposed within a shoe. In certain embodiments, the battery-receivingportion of the insole is a frame. The frame may be part of a heatingassembly that provides heat to a wearer's foot when powered by thebattery. The heating assembly is typically located within the insole anddelivers heat to at least the forefoot portion of the shoe. The heatingassembly may include a heating member and a connector, in addition tothe frame. The connector of the heating assembly may be operably coupledto the frame, and functions to transfer energy from the battery to theheating member. The heating member may include a heater panel and aconductive ribbon that transfers energy along a length of the insole tothe heater panel. The heating assembly may further include a circuitcoupled to the connector. The circuit allows one to adjust the level ofenergy being transferred from the battery to the heating member. Incertain embodiments, the circuit is adjustable from a remote control.

A benefit of the present invention is that the battery may be easilyinserted into and removed from the insole. The removable and insertablebattery is preferably designed to mate-fit with the frame of the insole.In certain embodiments, the battery is configured to fit within theframe while being directly removable from a surface of the insole.Ideally, a surface of the battery, when the battery is disposed withinthe frame, is substantially flush with a surface of the frame and/orinsole. This prevents the removable battery from being disruptive oruncomfortable to a user wearing the insole. The battery formed as partof a battery pack, which includes a body that encloses a battery cell.In addition, the battery may be rechargeable.

As discussed above, the frame may include a connector that providesenergy transfer from the battery to the heating member. Preferably, theconnector is configured to pivot to accommodate movement of the batteryinto and out of the frame. The pivoting movement advantageously allowsthe battery to mate-fit within the frame while also allowing one toinsert the battery into and remove the battery from the insole while theinsole is disposed within a shoe.

The insole of the invention may be an independent item that is separatefrom a shoe that the insole is being used with. In such case, the insoleis insertable and removable from the shoe. Alternatively, the insole ofthe invention can be built within or incorporated into the shoe itself(i.e. not designed for easy removal). Thus, the invention also includesa shoe having an insole that is configured to receive a removablebattery such that the battery may be inserted into and removed from theinsole with the insole disposed within the shoe.

Some aspects of the invention include a battery with a cushion portionthat is substantially flush with a surface of the insole. In addition,the battery, when disposed within the insole, may be removable from theinsole without removing the insole from the shoe. In certainembodiments, the battery is directly removable from a surface of theinsole. The battery may include a connector portion that mates with aconnector of the insole in order to provide energy transfer. The batterymay be a battery pack, which includes a body that encloses a batterycell. The battery may include a base portion that mates within a frameof the insole. The cushion portion (such as a foam cushion) may becoupled to the base portion. When the battery is installed in theinsole, the cushion portion forms a surface of the insole, and providescomfort to a user wearing a shoe with the insole disposed therein. Inaddition, the battery may be rechargeable.

Aspects of the invention further include assemblies for inclusion ininsoles. An assembly for inclusion in an insole may include a heatingmember and a frame with a connector. The assembly may be incorporatedinto an insole to form a heated insole. The assembly is for use inconjunction with a battery. The frame is designed to receive thebattery, which couples to the connector. In certain embodiments, theconnector pivots to connect and decouple from the battery. The connectorplaces the battery in electrical communication with the heating memberfor energy transfer. The heating member may include a heater panelcoupled to a conductive ribbon. A circuit may be included to adjust alevel of energy transmitted from the battery to the heating member. Thecircuit may be operated by a remote control. In certain embodiments, theassembly, when included in an insole, is configured to provide directremoval of the battery from a surface of the insole. In addition, theassembly, when included in an insole, preferably allows one to removethe battery from the insole when it is disposed within a shoe. Theabove-described assembly can also be incorporated directly into a soleof a shoe.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A illustrates a perspective view of an insole of the invention.

FIG. 1B illustrates a top view of the insole of FIG. 1A.

FIG. 1C illustrates a bottom view of the insole of FIG. 1A.

FIG. 2A illustrates a perspective view of a frame of an insole of theinvention.

FIG. 2B illustrates a top view of a frame of the insole of FIG. 2A.

FIG. 3A illustrates a perspective view of a battery of the invention.

FIG. 3B illustrates a side view of the battery of FIG. 3A.

FIG. 3C illustrates a front view of the battery of FIG. 3A.

FIG. 3D illustrates a top view of a battery of the invention, accordingto another embodiment.

FIG. 3E illustrates a rear view of the battery of FIG. 3D.

FIG. 3F illustrates a side view of the battery of FIG. 3D.

FIGS. 4A and 4B illustrate an insole of the invention disposed within ashoe.

FIG. 5 provides a partially transparent view of a heated insole 300according to certain embodiments.

FIG. 6 illustrates an exploded view of a heated insole according tocertain embodiments.

FIG. 7 illustrates an insulation layer of an insole of the invention.

FIG. 8 illustrates a water-proofing layer of an insole of the invention.

FIGS. 9A, 9B and 9C illustrate a configuration that allows bending of aheating assembly.

FIG. 10 illustrates a layout of a heating assembly of the inventionaccording to certain embodiments.

FIG. 11 illustrates a frame of a heating assembly according to certainembodiments.

FIG. 12 depicts a rivet used to connect a circuit to the frame of FIG.11.

FIGS. 13A and 13B illustrate a connector of the invention.

FIG. 14 illustrates a transparent side view of the connector of FIGS.13A and 13B.

FIG. 15 illustrates an exploded view of a battery of the invention.

FIG. 16 illustrates the coupling between a battery and a connector ofthe frame.

FIG. 17 illustrates a battery magazine of the invention.

FIG. 18 illustrates enlarged prospective view of a heel portion of aninsole of the invention, and shows a connector positioned at an incline.

DETAILED DESCRIPTION

While the invention is described herein as pertaining to heated insoles,concepts of the present invention are also applicable to other insolesthat may require battery power. For example, the structure andconfiguration of the present insoles with removable and insertablebatteries can be applied in insoles having a vibrating mechanism (e.g.massaging insoles). In addition, the invention is described in referenceto one insole and shows a left-footed insole, but it is understood thatthe invention could be used to form right-footed insoles or a pair ofinsoles (right-footed and left-footed insoles)

FIGS. 1A-1C illustrate views of an exemplary insole 100 according to theinvention. As shown in FIGS. 1A-1C, the insole 100 includes a body 28that has a distal end 24 and a proximal end 26, and can be divided upinto separate sections: a heel portion 2, a midfoot portion 4, and aforefoot portion 6. The heel portion 2 is typically thicker than themidfoot portion and forefoot portion 6 due to additional cushioning. Themidfoot portion 4 may be designed to support the arch of one's foot andprovides a transition between the heel portion 2 and the forefootportion 6. The forefoot portion 6 corresponds to the ball of one's footand toes. Preferably, the insole body 28 is shaped to conform to a foot(left or right) of a user. In addition, the insole body 28 may be shapedto fit within any type of shoes, including boots, tennis shoes, skiboots, sandals, slip-ons, etc. Ideally, the insole body 28 is flexiblesuch that it flexes with the motion of one's foot while they walk.

The insole body 28 includes a top surface 10, a bottom surface 22, aside surface 8. The top surface 10 receives the foot of a wearer, andthe bottom surface 22 rests against the sole (bottom frame) of the shoe.The top surface 10 or bottom surface 22 may be specially formed toconform to different types of feet and different types of shoes. Inaddition, the bottom surface 22 may rest or be designed to rest againstanother insole (i.e. for when the shoe has built-in insoles). The insolebody 10 may be formed, at least in part, by a cushioned material toprovide comfort to the user. Furthermore, the insole body 28 may beformed as part of the sole of a shoe. For instance, when the shoe, dueto its structure, does not have an insole separate from the sole itself,which is often the case in slip-on shoes.

The insole body 28 of the insole 100 includes a frame 12 that isconfigured to receive a battery 14 disposed therein. Preferably, theframe 12 is positioned in the heel portion 2 of the insole 100, or inthe arch segment of the insole 100. The top surface 20 of the frame issubstantially flush or flush with a top surface 10 of the insole body28. As shown in FIGS. 1A and 1B, the battery 14 is shown inserted in theframe 20. The top surface 30 of the battery 14 is substantially flush orflush with the top surfaces 10, 20 of the insole body 28 and frame 12,respectively. This flushness advantageously allows a user to comfortablyrest his/her foot against the insole 100 without feeling differencesamong the multiple components. In addition, top surfaces 20, 30 of theframe 12 and battery 14 may be cushioned in the same manner as theinsole body 28 to further prevent a wearer from feeling or beingdisrupted by the multiple components. For example, each component may beformed from a polymer or polymer foam. A preferred polymer or polymerfoam is polyurethane. Alternatively, the components may be formed fromdifferent materials.

The frame 12 optionally includes a grasping region 18 that is shaped toallow a user to directly remove the battery 14 from the top surface 10of the insole body 28. That is, one does not have to remove the battery14 from an enclosed battery compartment (i.e. with a lid for example),but can access the battery from the outer surface of the insole. Asshown, the grasping region 18 is a recess within the frame 12 next tothe battery 14. Preferably, the grasping region 18 is shaped to allow awearer to partially insert one or more fingertips therein so that thewearer can use their fingertips to easily remove the battery 14. Thegrasping region 18 may be positioned anywhere within the frame 12, andis shown on a distal portion of the frame 12.

According to certain aspects, insoles 100 of the invention may beinserted and removed into one's shoes when one desires. In such aspect,the insole is a separate from the shoe. For removable insoles, theinsole 100 may include a tab 16 that a user can pull to remove theinsole 100 from the inside of a shoe. Alternatively, insoles 100 of theinvention may be built into one's shoes (e.g. not designed for easyremoval).

FIGS. 2A and 2B provide a close-up view of the frame 12 without abattery inserted therein. The frame 12 defines a recess 40 that issurrounding by sides 42 and bottom 44. The recess 40 of the frame 14 issized and shaped to receive the battery 14. Preferably, the frame 12snuggly receives the battery 14 within the recess 40 to preventunintended movement or removal of battery 14. The frame 12 furtherincludes a connector 46. The connector 46 couples to the battery 14, andplaces the battery 14 in communication with a heating member (discussedhereinafter). In certain embodiments, the coupling between the connector46 and the battery 14 is a mate-fit coupling (the particulars of whichare described in more detail hereinafter). The connector 46 ispreferably constructed out of an elastomeric material, which providesthe ability to absorb deflection and stress. The connector 46 may pivotto assist in battery 14 insertion and removal (this function isdescribed in more detail hereinafter). The pivoting capability andflexibility of the connector 46 allow it to maintain its mechanicalintegrity even when deflecting while bearing weight and other stresses.

In certain embodiments and as shown in FIG. 2A, the frame 12 may includea rigid portion 52 and a cushion portion 50. The cushion portion 50provides comfort to the user, and the rigid portion 52 provides theneeded structural support for the connector 46 and associated circuitry.The cushion portion 50 may be a polymeric foam.

In certain embodiments, the frame 12 of the insole 100 includes abattery indicator. The battery indicator may include light emittingdiode (LED) that is associated with circuitry (such as circuit 210 shownin FIGS. 5 and 6) disposed within the insole. In one embodiment, thebattery indicator emits a light when the battery 14 is inserted into theinsole 100. The emitted light my indicate that the battery 14 is fullyconnected and may appear as a single flash, a series of flashes overtime, or the light may constantly be emitted while the battery is inplace. Optionally, the battery indicator also emits a light toillustrate that the battery 14 is running low on charge. The low-batterylight may appear as a single flash, a series of flashes over time, orconstantly emitted light. Preferably, the light emitted to indicate thatthe battery is properly inserted or connected is different from thelight emitted to indicate the battery is low on charge. For example, agreen light may indicate the battery is properly inserted, and a redlight may indicate the battery needs to be recharged. In addition, thebattery indicator may also emit a light to illustrate that the battery14 is defective, and should be discarded.

The battery indicator may be positioned anywhere on the insole 100.According to some embodiments, the battery indicator is positioned onthe frame so that it is easily visible to a user while the insole isdisposed within a shoe. FIG. 2B shows a battery indicator 27 positionedin the grasping region 18 of the frame 12. In this particularembodiment, the battery indicator 27 includes an LED in close proximitywith an opening of the grasping region 18 of the frame 12. The frame 12near the battery indicator 27 may include a reflective surface tofurther enhance the light emitted from the LED. The opening allows lightemitted from an LED, which is associated with the internal circuitry ofthe insole, to be seen therethrough.

The battery 14 may be the battery itself (i.e. one or more batterycells) or a battery pack, which is a body that encloses one or morebattery cells. Any suitable battery may be used for the battery orbattery cell. Types of batteries include, for example, nickel cadmium,nickel-metal hydride, lead acid, lithium ion, lithium ion polymerbatteries. The battery chosen ideally holds charge for more than 2, 3, 4or 5 hours, and is rechargeable. In one aspect, the battery 14 is abattery pack, and such aspect is described hereinafter and shown inFIGS. 3A-3C. The battery can be inserted and removed from the insole (orsole) at the user's convenience.

FIGS. 3A-3D illustrate battery 14 as a battery pack according to certainembodiments. Preferably, the battery 14 is shaped to fit within theframe 12 such that the top surface of the battery 14 is substantiallyflush or flush with top surfaces of the frame 12 and insole body 28. Insome embodiments, the battery 14 includes a lower body portion 62 and anupper body portion 64. The lower body portion 62 may be formed from apolymeric material, and the upper body portion 64 may be a polymericform. The lower body portion 62 is designed to mate fit with the rigidportion 52 of the insole frame 12. The lower body portion 62 alsoincludes a connector portion 66 that is designed to couple (i.e.mate-fit) to the connector 46 of the frame 12. In certain embodiments,the lower body portion 62 is also rigid to protect the battery celldisposed therein and to protect the coupling between the batteryconnector 66 and the frame connector 46. The lower body portion 62 mayinclude a door or latch that allows one to remove the battery cell(s)disposed therein. The upper body portion 64 is coupled to the lower bodyportion 62. Preferably, the upper body portion 64 is cushioned toprovide comfort to a user.

According to certain embodiments, the battery 14 includes a finger tab67 that one can leverage with his/her finger to assist in removing thebattery 14 from the frame 12. The finger tab 67 can extend from thelower body portion 62, and may be positioned on any side of the battery14. Preferably, the finger tab 67 is on a side of the battery 14 thatmates with the grasping region 18 of the frame 12. As shown in FIG. 3B,the finger tab 67 is positioned at the distal end of the lower bodyportion 62, which is opposite to the connector 66, and is level with thetop of the lower body portion 62.

In preferred embodiments, the lower body portion 62 and the upper bodyportion 64 are designed to accommodate a raised finger tab 69, as shownin FIGS. 3D-3E. In such embodiment, one side (such as the distal end) ofthe lower body portion 62 may include a raised portion 70 from which theraised finger tab 69 extends. In addition, one side (such as the distalend) of the upper body portion 64 may include a cut-out 71 toaccommodate the raised portion 70. The raised finger tab 69 furthereases one's ability to remove the battery 14 with his/her fingertip.

A benefit of insoles of the invention is that the battery 14 may beremoved from the insole 100 while the insole is disposed within a shoe.FIGS. 4A and 4B graphically illustrate an insole 100 of an inventiondisposed within a shoe 200. The insole 100 is placed within a shoe 200such that the bottom surface of the insole rests against, for example, asole of the shoe 200. The battery 14 of the insole 100 is positioned atthe heel portion of the insole such that the battery 14 is accessiblefrom the shoe opening 202. The battery 14 may be conveniently insertedinto and removed from the shoe 200, while the insole 100 is disposedwithin the shoe, by simply reaching one's hand into the shoe opening 202and grabbing the battery 14. This allows one to quickly replace a usedbattery for a charged battery, without having to remove the insole orwait for an internal battery of the insole to charge. In addition, theused battery may be recharged while the charged battery is being used.For example, the used battery may be charged in the charging magazineshown in FIG. 17.

As discussed above, insoles of the invention with removable batteriesare particularly well-suited for use as heated insoles. FIG. 5 providesa partially transparent view of a heated insole 300 according to certainembodiments. The heated insole 300 (like insole 100) includes an insolebody 28, a frame 12 disposed in the heel portion of the insole, and abattery 14 placed within the frame 12. The surfaces of the battery 14,frame 12, and insole body 28 may be substantially flush with each other.The battery 14 may be removed directly from the surface of the insolebody 28. In addition, the battery 14 may be removed from the insole 300while the insole 300 is disposed within a shoe. The heated insole 300further includes a heating assembly 220, which is described in moredetail hereinafter. The heating assembly 220 is coupled to the battery14 via the connector 46 (not shown in FIG. 5) of the frame 12.Optionally, the heating assembly 220 includes a circuit 210. The heatingassembly 220 extends from the heel portion to the forefoot portion ofthe insole body 28. The heating assembly 220, when powered by thebattery 14, provides heat to a wearer of shoe having the insole 300disposed therein. In addition, the heating assembly 220 may be flexiblesuch that it flexes in response to a wearer's movement.

FIG. 6 illustrates an exploded view of the components of the heatedinsole 300. The main components of the insole body 28 include a toplayer 302, a heel cushion 306, and a bottom layer 304. The top layer 302and the heel cushion 306 include openings 308, 310 (respectively). Theopenings 308, 310 are designed to receive the frame 12. The frame 12 isdesigned to receive the battery 14. The battery 14 includes a lower bodyportion 62 (e.g. a rigid body that encases a battery cell) and an upperbody portion 64 (e.g. cushioned body).

The heated insole 300 further includes a heating assembly 220. As shownin FIG. 6, the heating assembly 220 includes the frame 12, a ribboncable 312, and a heater panel 314. As discussed above, the insole layers(top layer 302 and heel cushion 306) include openings 308, 310(respectively) that are shaped to receive the frame 12. The frame 12includes a connector 46 that electrically couples to a connector of thebattery 14, when the battery 14 is placed within the frame 12. Theheater panel 314 may be any desirable shape. As shown, the heater panel314 is a flat, substantially rectangular shape designed to fit withinthe forefoot portion of the insole. The ribbon cable 312 (or otherconductive material) delivers electric current from the battery 14, whencoupled to the connector 46, to the heater panel 314. Preferably and asshown, the ribbon cable 312 is coupled to a circuit 210. In a preferredembodiment, the ribbon cable 312 has a first end that is soldered orotherwise electrically connected to circuit board 210 and a second endthat is connected to the heater panel 314. The circuit 210 is configuredto adjust the level of energy transferred from the battery 14 to theheater panel 314. For example, the circuit 210 may be programmed toprovide certain heating levels, e.g., low, medium, and high. In someembodiments, the circuit 210 may be operably associated with atemperature sensor, and the circuit 210 delivers energy to maintain acertain threshold temperature level (such as body temperature) inresponse to readings transmitted from the temperature sensor. In certainembodiments, the circuit 210 may be controlled by a remote control (notshown). In such an embodiment, the circuit 210 includes a receiver thatreceives signal from a remote, decodes the signal, and then the circuit210 executes the operation based on the signal. In embodiments thatinclude a battery indicator 27, the circuit 210 controls an LED of thebattery indicator. For example, the circuit 210 may cause the LED toemit light as discussed in more detail above. In addition, the circuit210 may cause the LED to emit light upon receipt of a signal from theremote control.

Remote control technology is generally known, and relies on sending asignal, such as light, Bluetooth (i.e. ultra-high frequency waves), andradiofrequency, to operate a device or circuit. Dominant remote controltechnologies rely on either infrared or radiofrequency transmissions. Aradiofrequency remote transmits radio waves that correspond to thebinary command for the button you're pushing. As applicable to thepresent insoles, the command may include high heat, low heat, mediumheat, on, or off. A radio receiver on the controlled device (e.g.circuit 210 of heating assembly 220) receives the signal and decodes it.The receiver then transmits the decoded signal to the circuitry, and thecircuitry executes the command. The above-described concepts forradiofrequency remote controls are applicable for light and Bluetoothremote controls.

According to certain aspects, all electrical and electronic components(i.e. connector 46, circuit 210, ribbon cable 312, and heater panel 314)are completely coated or sealed with water proofing sealants, coatings,and water tight encapsulating means coating to enable the circuit tofunction well when exposed to moisture and water.

According to certain embodiments, the heated insole 300 further includesinsulation and water-proofing. For example, the ribbon cable 312 andheater panel 314 may be sandwiched between an insulation layer 316 below(also shown in FIG. 7) and a water-proofing layer 318 above (also shownin FIG. 8). Water proofing layer 318 may be made of any of various wovenor non-woven materials, which allow heat to pass there through.Insulation layer 316 supports the heater panel 314, ribbon cable 312 andthe circuit board 210—all of which are placed on the top face ofinsulation layer 316. The insulation layer 316 has a contact region 320which abuts the frame 12. The ribbon cable 312, heater panel 314,insulation layer 316 and water proofing layer 318 are aligned with thecircuit board 210. The circuit board 210 is attached to the frame 12with a rivet that connects the circuit board 210 to the battery frame12. See, for example, FIGS. 11-12. The rivet allows variation in theangle between the frame 12 and ribbon cable 312/circuit board 210/heaterpanel 314.

According to certain aspects, the design of the heating assembly 220 isflexible in order to allow the heating assembly 220 to withstand thestress and pressure accompanied by movement of a wearer. In someembodiments, the underlying insulation layer 316 includes an opening 326that allows the ribbon cable 312 to release an amount of longitudinalstress by protruding excess length thereof into the opening 326. Forexample and as shown in FIG. 9A, the opening 326 is a substantiallyrectangular slot or groove that is slightly wider than ribbon cable 312.When the insole 300 is in its flat state, the ribbon cable 312 is laidflat in straight line between the heater 314 and the circuit board 210without any excess length in the cable. When the insole 300 bends, theribbon cable 312 and insulation 316 also bend (as shown in FIGS. 9B and9C). Due to the ribbon cable's 312 fixed length, it needs room to moveduring bending or else buckling occurs. The slot 326 receives the excessribbon cable 312, thereby eliminating stress on the ribbon cable's 312electrical connections due to the bending of the insole 300. This helpsto protect the ribbon cable 312 and its electrical connections frombeing torn or compromised by bending and sheering stresses. In certainembodiments, the heater panel 314 is attached to insulation layer 316 ina manner that allows slight movement of the heater panel 314 as theinsole 300 bends. This relieves bending stress on the heater panel 314caused by the bending of the insole 300. For example, in one embodiment,the heater panel 314 is glued, riveted or otherwise connected at one endthereof to the underlying insulation layer 316. The insulation layer 316is preferably formed from a soft, pliable material, which allows some“give” when the heater panel 314 is pulled by ribbon cable 312 duringbending.

Referring now to FIG. 7, the insulation portion 316 has a contact region320 that abuts the frame 12. The contact region 320 is designed to beused interchangeably in right and left shoes. To that end, and as bestshown in FIG. 7, the terminal end 350 of contact region 320 anglesoutwardly to create two different attachment ends. As shown, wall 350 aemanates from a first corner 354 a of the contact region 320 and anglesoutwardly. Wall 350 b similarly emanates for a second corner 354 b andangles outwardly. Walls 350 a and 350 b meet at apex 352. This geometryenables the insulation layer 316 and the heater 314 to be assembled in arange of angles so the same assembly would fit into left and right shoeswith varying sizes. This geometry is described further in reference toFIG. 10.

FIG. 10 shows a bottom transparent view of an insole 300 according to anembodiment of the invention. As shown, an insole 300 is slightly angledfrom heel (proximal end 26) to toe (distal end 24). In order tosubstantially center the heater panel 314 in the forefoot portion 6 ofthe insole 300, the heater panel 314 must be somewhat offset withrespect to the heel portion 2. As illustrated by the dotted line 44 inFIG. 10, if the ribbon cable 312 and heating element 314 would emanatefrom the frame 12 in a substantially linear manner—the heating element314 would not be substantially centered in the forefoot portion 6, butrather it would be skewed to one side of the forefoot portion 6. Howeverbecause, as shown, wall 350 a abuts the frame 12 and because wall 350 ais angled, the trajectory of the ribbon cable 312 and heating element314 is slightly angled so as to position the heating element 314 in thegeneral center of forefoot portion 6. As shown in FIG. 10, wall 350 a isused as a contact surface in a left shoe. Wall 350 b may be used as acontact surface of a right shoe. The angled terminal end 350 of thecontact region 320, thus, allows the ribbon cable 312 and heating panel314 to be used in any shoe.

The above-described features of the heating assembly 220 (e.g.flexibility and angled nature due to contact region) beneficially allowthe heating assembly 220 to be incorporated in an insole or sole of awide variety of shoes, including worker boots, tennis shoes, hikingboots, skiing shoes, snow shoes, etc. In addition, the above-describedfeatures allow one to use the same manufacturing process to produceheating assemblies for both right and left insoles.

FIG. 11 illustrates a close up view of the frame 12 that may be used ininsoles of the invention. The frame 12 includes connector 46 and definesa recess 40 that is surrounding by sides 42. The recess 40 of the frame14 is sized and shaped to receive the battery 14. The frame furtherincludes extension member 370. The extension member 370 includes a rivetopening 462. A rivet associated with the circuit 210 (as shown in FIG.6) may couple to the frame 12 via rivet opening 462. FIG. 12 illustratesa rivet 372 suitable for coupling the circuit 210 to the frame 12.Preferably, the rivet 372 is flexible such that it can deflect withoutbreaking. A flexible rivet maintains the integrity of the connectionbetween the frame 12 and the circuit board 210 despite bending of theinsole 300. In certain embodiments, the rivet 372 is made from atechnical grade elastomeric material.

As discussed above, the connector 46 of the frame 12 may, according tocertain embodiments, pivot or rotate in order to connect to the batteryas it is placed directly into the frame 12. This pivoting motion allowsthe battery 14 to snuggly fit within the recess of the frame 12. Withoutthe pivoting motion, the frame 12 and its recess may have to be largerthan the battery in order to accommodate the lateral motion required toconnect the battery 14 to the connector 26. FIG. 18 illustrates anenlarged view of the heel portion of an insole with the connector 46positioned at an incline. The angle of the incline can vary depending onapplications and the amount of pivot one desires. In certainembodiments, the connector may be configured to rotate, for example,10°, 20°, 30°, . . . , 80°, 90°.

FIGS. 13A and 13B illustrate an exemplary design of the connector 46.The connector 46 includes one or more hinges 510. The hinges mate withindents in the frame 12 (not shown). The hinge 510 allows the connector46 to pivot/rotate upwardly in order to align with a battery 14 to beinserted. The connector may be formed from a polymer, plastic, rubber,and/or thermoplastic elastomeric material. The connector 46 ispreferably constructed out of elastomeric material giving it the abilityto absorb deflection and stress. The above-mentioned features of theconnector 46 allow the connector 46 to maintain its mechanical integrityeven while deflecting and being subjected to external stresses (e.g.pressure from a wearer's movement).

According to certain embodiments and as shown in FIG. 13A, the connector46 includes one or more electrical contact housing members 512.Electrical contacts (best shown in FIG. 16) are housed inside of thehousing members 512, and are accessible through openings 502. Theelectrical contact housing members 512 mate fit with a connector portion66 of the battery 14. In particular embodiments, the connector portion66 of the battery 14 defines a recess 19 that includes an internalseparator 17. See, for example, FIG. 3C. When the battery 14 is coupledto the connector 46, the internal separator 17 is positioned between theelectrical contact housing members 512. Thus, the internal separator 17acts to guide the housing members 512 into place as the battery 14coupled to the connector 46. Electrical contacts (as shown in FIG. 16)within the housing members 512 are then coupled to battery pins 21 thatare positioned in the battery recess 19. When the contact points arecoupled to the battery pins 21, energy from the battery 14 can betransferred to the heater panel 314 via the connector 46.

As further shown in FIG. 13A, the outer walls of the connector 46, whichface the battery, may have angled geometry 504 to help guide theelectrical contact housing members 512 into the battery recess 19. Incertain embodiments, the connector 46 further includes one or moreridges 508 for water proofing. When the battery 14 is fully engaged withthe connector 46, the ridges 508 prevent water from entering the batteryrecess 19 and disrupting the electrical connection.

FIG. 13B illustrates a back side of the connector 46, which is incommunication with the heating assembly 220. The back side of theconnector 46 may include one or more openings 520 or similar cutouts forallowing wires or similar conductors to pass out of the connector 46.Those conductors/wires are in electrical communication with theelectrical contacts 537 (as shown in FIGS. 15 and 16) of the connector46 and may be coupled to the circuit 210, ribbon cable 312, or both. Theopenings 520 are sealed with a water proof sealant to protect the wiresfrom water or other elements. The back side of the connector 46 may alsoinclude a lip 522, which is used as a height gauge for the wires andsealant compound during the assembly of the connector 46. Lip 522presents a physical barrier which limits the amount of sealant compoundthat may be introduced into the area there below. This preventsexcessive build-up of sealant materials—which may prevent or limitmovement of the connector 46.

FIG. 14 shows a side, transparent view of a connector 46. As shown, astructural recessed round cavity 518 inside of the connector 46 isfilled with the sealant and keeps the sealant in place to help maintainany sealant that is introduced through openings 520 from loosening andcompromising the water tight seal.

As discussed above, the insoles of the invention are designed to receivea battery 14. See, for example, FIGS. 3A-3C. In certain embodiments, thebattery 14 may be a battery pack. A battery pack includes a bodyenclosing a battery cell. The body may be the lower body portion 62, asshown in FIGS. 3A-3C. FIG. 15 illustrates an exploded view of the lowerbody portion 62. As shown in FIG. 15, the lower body portion 62 of thebattery pack includes a boxed portion 602. The boxed portion 602 definesa recess to receive the battery cell 604 and includes the connectorportion 66 (which couples to the connector 46 of the frame 12). Abattery cell 604 may be placed in the recess. The boxed portion 602 mayinclude a locking ridge 608 or tab on the side opposite of the connectorportion 66. Optionally, the locking ridge 608 meets with an indent inthe frame 12, when the battery 14 is placed in the frame, in order toprevent undesirable movement of the battery 14 while still allowing thebattery 14 to be removed from the frame upon application of upward force(e.g., manual removal). The battery cell 604 is enclosed in the boxedportion 602 via lid 606. The lid 606 may be permanently attached to thebattery box 602 or the lid 606 may be removable to allow one to swap thebattery cell 604. The lid 606 includes a finger tab 67 that one canleverage with his/her finger to assist in removing the battery 14 fromthe frame 12. When the lid 606 is removable, the finger tab 67 may alsobe used to remove the lid 606 from the boxed portion 602. Whenassembled, the pins 21 of the connector portion 66 are in electricalcommunication with the battery cell 604.

FIG. 16 provides a transparent view of the battery 14 coupled to theconnector 46 of the frame, according to certain embodiments. As shown inFIG. 16, the pins 21 of the battery 14 enter the electrical contacthousing members 512 of the connector 46, which places the pins 21 inelectrical communication with the electrical contacts 537. Ideally andas shown, the inners walls of the recess 19 of the connector portion 66include one or more slanted segments 540. The slanted segments press onthe edges of the connector 46 when the battery is inserted all the wayinto the connector, this pressure forces the electrical contacts 537 topress against the pins 21, and maintain such contact.

FIG. 17 shows a battery magazine for charging and transportingbatteries, according to certain embodiments. As shown in FIG. 17, thebattery magazine is a frame 700 forming one or more recesses 702, eachconfigured to receive a battery. The frame 700 of the magazine isconfigured to hold one or more connectors 746 (which are ideally thesame as pivoting connector 46 of frame 12). The connectors 746 may becoupled to electrical cord that allows the connectors 746 to charge oneor more batteries when the electrical wiring is plugged into anelectrical outlet. In alternative embodiments, the battery magazine mayinclude a USB socket that is coupled to the connectors 746. In suchembodiments, a USB adaptor may be used to charge the batteries. Thebattery magazine may also include a circuit, such as a printed circuitboard, disposed within the magazine and operably associated with theconnectors 746. A function of the circuit includes monitoring chargingof the battery to prevent under- or over-charging of the batteries. Thecircuit may be operably associated with one or more LEDs. In oneembodiment, the battery magazine includes LEDs for each battery that themagazine is designed to receive. In this embodiment, the circuit can beconfigured to cause each LED to emit light in order to convey one ormore functions with respect to one or more batteries in the magazine.The one or more functions may include, for example, showing thefollowing: battery is connected, battery is charging, battery ismalfunctioning, and battery is fully charged. The light emitted from theLED may be same or different for each function. For example, the lightmay be a different color for the one or more functions, or the light maybe emitted in the same or different manner (single pulse, series ofpulses, or constant light) for the one or more functions.

Portions of the insole (such as the frame) and the battery (such as thelower body portion) may be formed from any suitable plastic, polymer, orpolymeric blend. Suitable materials may include Polyethyleneterephthalate (PET), Polyethylene (PE), High-density polyethylene(HDPE), Polyvinyl chloride (PVC), Polyvinylidene chloride (PVDC),Low-density polyethylene (LDPE), Polypropylene (PP), Polystyrene (PS),High impact polystyrene (HIPS), etc. The material of the frame and thebattery may be the same or different. In addition, the material of theinsole body and the layers of the insole may depend on the need of theinsole (e.g. what activity will the insole be used for). These insolematerials may be plastic, polymer, rubber, thermoplastic elastomericmaterial, leather, cotton, and polymer foams. Preferred polymer foamsinclude polyurethane foams.

The invention may be embodied in other specific forms without departingfrom the spirit or essential characteristics thereof. The foregoingembodiments are therefore to be considered in all respects illustrativerather than limiting on the invention.

The invention claimed is:
 1. A heated insole for a shoe, the insole comprising an insole body including a battery-receiving portion; a heating member disposed within the insole body and associated with the battery-receiving portion; a battery configured to be removable from and insertable into the battery-receiving portion while the insole is disposed within the shoe; and a connector associated with the battery-receiving portion and configured to transmit energy from the battery to the heating member, the connector pivots to connect to and disconnect from the battery.
 2. The insole of claim 1, wherein the battery is rechargeable.
 3. The insole of claim 1, wherein the battery, when disposed within the battery-receiving portion, is directly removable from a surface of the insole body.
 4. The insole of claim 1, wherein a surface of the battery, when the battery is disposed within the battery-receiving portion, is substantially flush with a surface of the insole body.
 5. The insole of claim 1, wherein the battery-receiving portion is located at the heel of the insole body.
 6. The insole of claim 1, further comprising a circuit operably coupled to the connector, the circuit configured to adjust a level of the energy transmitted from the battery to the heating member.
 7. The insole of claim 6, wherein the circuit is adjustable from a remote control.
 8. The insole of claim 1, wherein the battery comprises a battery pack that encloses a battery cell.
 9. The insole of claim 8, wherein the battery pack comprises a cushion portion.
 10. The insole of claim 9, wherein a surface of the cushion portion, when the battery is disposed within the battery-receiving portion, is substantially flush with a surface of the insole.
 11. The insole of claim 1, wherein the heating member comprises conductive ribbon and a heater panel.
 12. The insole of claim 1, wherein the heating member delivers heat to at least a forefoot portion of the insole body. 